• Transactions of the Korean Society of Mechanical Engineers A
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• v.21 no.12
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• pp.2055-2067
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• 1997

Values of process parameters in sheet metal forming can be estimated by various one-step inverse methods. One-step inverse methods based on deformation theory, however, cause some amount of error. The amount of error is generally increased as the deformation path becomes more complex. As a remedy, a new three dimensional multi-step inverse method is introduced for optimum design of blank shapes and strain distributions from desired final shapes. The approach extends a one-step inverse method to a multi-step inverse method in order to reduce the amount of error. The algorithm developed is applied to square cup drawing to confirm its validity by demonstrating reasonably accurate numerical results. Rapid calculation with this algorithm enables easy determination of an initial blank of sheet metal forming.

• Transactions of the Korean Society of Mechanical Engineers
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• v.17 no.6
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• pp.1389-1403
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• 1993

A procedure has be developed to optimize the product's tipping position in designing a die face for manufacturing automobile outer panels. Two design requirements are considered in optimizing the tipping position. One is to satisfy that all the points on the product should have a uniform distribution of drawing depths. The other is to guarantee that the user-specified area on the product should first contact with the binder wrap. The problem to satisfy the design requirements described above is analogous to the flatness calculation problem in the area of metrology if some constraints can be imposed. Thus the problem can be solved by the simulated annealing method, which is one of the optimization methods. The developed procedure was tested with the real die face design problem and the usefulness was verified by the diagram of the drawing depth.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.38 no.8
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• pp.899-904
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• 2014

Thickness profiled blank is designed using optimization techniques for maximizing the bulged heights during the free bulging of Inconel 718. The thickness of the blank was described by the Bezier curve and the locations of the control points were used as the design variables for optimization. The maximization of the bulged heights within the limited strain range served as the objective function and constraints for optimization. The equivalent static loads method for non-linear static response structural optimization (ESLSO) was used and the result of the optimization revealed 22 increased bulged heights. A free bulging test using a blank with an optimized profile was conducted to verify the optimization process. The results were compared with those of numerical analysis in terms of bulged height and deformed shape.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2003.05a
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• pp.283-287
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• 2003

In recent years, design of an optimal blank shape is very important for sheet metal forming process in the automobile industry because the raw material cost rate is significant part in the automobile industry. With the design of an optimal blank shape, the engineer can protect a blank from an excessive holding force to improve the quality and reduce the ratio of material scrap. Therefore design of an optimal blank shape is inevitable in sheet metal forming process. However, if it causes a complicated shape of blank, it may be difficult to do the blank layout optimally. In this study, we developed software of optimal blank layout connected with the software of optimal blank shape design which was created in the past by the present authors. And by using these softwares, we would like to present the method in order to get optimal utilization ratio easily and precisely within short time for the sequence of works from design to blank layout.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.36 no.11
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• pp.1361-1370
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• 2012

A shape optimization is proposed to obtain the desired final shape of forming and forging products in the manufacturing process. The final shape of a forming product depends on the shape parameters of the initial blank shape. The final shape of a forging product depends on the shape parameters of the billet shape. Shape optimization can be used to determine the shape of the blank and billet to obtain the appropriate final forming and forging products. The equivalent static loads method for non linear static response structural optimization (ESLSO) is used to perform metal forming and forging optimization since nonlinear dynamic analysis is required. Stress equivalent static loads (stress ESLs) are newly defined using a virtual model by redefining the value of the material properties. The examples in this paper show that optimization using the stress ESLs is quite useful and the final shapes of a forming and forging products are identical to the desired shapes.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1997.03a
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• pp.179-182
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• 1997

One-step inverse methods based on deformation theory causes some amount of error. The amount of error is generally increased as the deformation path is more complex. As a remedy, a new three dimensional multi-step inverse method is introduced for optimum design of blank shapes and strain distributions from desired final shapes. The approach extends a one-step inverse method to a multi-step inverse method in order to reduce the amount of error. The algorithm developed is applied to square cup drawing to confirm its validity by demonstrating reasonably accurate numerical results.

• Transactions of Materials Processing
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• v.13 no.1
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• pp.90-101
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• 2004

An inverse mosaic method has been proposed to generate an initial blank shape from the final product shape. Differently from the geometric mapping method, the method can handle triangular patches. However, the generated blank shape is strongly dependent on the order of determination of nodes. In order to compensate the dependency error smoothing technique has been also developed. Although the accuracy has been improved greatly compared with the geometrical mapping method, the method has limitation, due to the no incorporation of plasticity theory. Even though the accuracy of the radius vector method is already proved. the method requires initial guess to start the method. In order to compromise the limitation of the present method and the radius vector method, the method has been connected to the radius vector method. The efficiency of the present optimal blank design method has been verified with some chosen examples.

• Transactions of Materials Processing
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• v.24 no.1
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• pp.28-36
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• 2015

After a short review of the iterative optimal blank method, a new method of measuring the shape error for stamped parts with 3D contour lines, which is an essential component of the optimal blank design, is proposed. When the contour line of the target shape does not exist in a plane, but exists in 3D space, especially when the shape of the target contour line is very complicated as in the real automotive parts, then the measurement of the shape error is critical. In the current study, a method of shape error measurement based on the minimum distance is suggested as an evolution of the radius vector method. With the proposed method, the optimal blank shapes of real automotive parts were found and compared to the results of the radius vector method. From the current investigation the new method is found to resolve the issues with the radius vector method.

• Transactions of Materials Processing
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• v.10 no.1
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• pp.15-22
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• 2001

The sensitivity method has been utilized to find initial blank shapes which transform into desired shapes after forming. From the information of die shapes, target shape and material properties, the corresponding initial blank which gives final shape after deformation has been found. Drawings of a trapezoidal cup, a cross-shaped cup and an oil pan have been chosen as the examples. At every case the optimal blank shape has been obtained only a few times of modification without any predetermined deformation path. With the predicted optimal blank, both computer simulation and experiment are performed. Excellent agreements are recognized between simulation and experiment at every cases Through the investigation, the sensitivity method is found to be effective in obtaining optimal blank shapes in drawing of complex shapes.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.17 no.10
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• pp.696-701
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• 2016

Multi-stage deep drawing is a widely used industrial manufacturing process, and its applications are gradually expanding to both small products and large metallic products. The USB C-type socket used in smart phones, for example, is manufactured using oval multi-stage deep drawing. The socket is very small and slender and it requires precise manufacturing. The thickness distribution of the final product is guaranteed only if it is uniform throughout the overall process. Therefore, minimizing the height difference between long and short sidewalls after the first operation is important for this goal. An initial blank optimization was performed for an oval-type drawing process based on finite element simulations. The goal was to determine an initial blank geometry that can maintain uniform height and thickness after the first draw operation. The initial blank shape of the sheet metal was optimized, and the results show that it satisfied the conditions of minimal thickness reduction and even thickness distribution. The geometry from the optimized simulation was compared with experimental results, which showed good agreement.